Snowmobile Polaris Two Stroke (2007 year). Manual - part 19

3.19

MAINTENANCE

3

After setting the throttle lever free play, always verify the oil
pump adjustment is set correctly.

Oil Pump Adjustment

NOTE:  Use a mirror to accurately view the alignment
marks.

1.

On some engines the oil pump is located under the intake
boots and you may have to remove the air box and may
need to unplug the CDI box and coils.

2.

Verify carburetor/throttle body synchronization.

3.

Loosen the carburetor boot adapters and carefully move
them so that you can see and adjust the oil pump cable.

4.

Verify that the oil pump alignment marks are aligned at the
point where the throttle slides begin to rise from their fully-
closed positions.

5.

If they are not aligned, make the necessary adjustments by
adjusting the oil pump cable. In small increments, loosen
the lock nut that is closest to the oil pump (A). and move
the mark that is on the oil pump arm by tightening or
loosening the adjustment nut (B) as needed to get the line
to the desired position.

6.

Lock the lock nut (A).

7.

Verify that the oil pump marks line up (C) as outlined in
step 4.

8.

Re-install carburetors, air box and plug in the CDI and coils
if they were taken off in step 1.

9.

Check idle to specification and adjust if needed.

A

B

C

600 IQ HO

3.20

MAINTENANCE

Track Alignment

NOTE:  Track alignment affects track tension.
Misalignment of the track will cause excessive wear
to the track, rail slides, and rail.

NOTE:  Excessive rail slide wear occurs due to
running in inadequate snow conditions.

Periodically check that the track is centered and running evenly
on the slide rails. Misalignment will cause excessive wear to the
track and slide rails.

1.

Safely lift and support the rear of the snowmobile off the
ground.

2.

Rotate the track by hand to check for any possible damage.

3.

Inspect the track rods (A) carefully and examine the track
along the entire length of each rod, bending the track edge
and inspecting it for breakage. If any rod damage is found,
the track should be replaced.

4.

Warm up the track by starting the engine and apply a small
amount of throttle so the track runs slowly at least five
complete revolutions.

5.

Stop the engine and turn the ignition off.

6.

Inspect track alignment by carefully looking through the
track window (B) to make sure the rails (C) are evenly
spaced on each side. 

7.

If the track runs to the left, loosen the left locknut and
tighten the left adjusting bolt (D). If the track runs to the
right, loosen the right locknut and tighten the right adjusting
bolt. It may be necessary to check this with the engine
rotating the track. Be sure to SHUT THE MACHINE OFF
before making any further adjustments.

8.

Loosen up the rear idler shaft (F). 

9.

After any adjustments are complete, be sure to torque the
locknuts (E) to 35 ft-lb (48 N-m).

10. Torque both idler shaft bolts (F) to 35 ft-lb (48 N-m).

A

B

C

D

E

F

= T 

Adjuster Lock Nuts: 35 ft-lb (48 N-m)

= T 

Idler Shaft Bolt: 35 ft-lb (48 N-m)

WARNING

Broken track rods can cause a rotating track to come off 
the machine. Never operate or rotate a damaged track 
under power with a broken rod. Serious injury or death 
may occur.

WARNING

When performing the following checks and 
adjustments, stay clear of all moving parts to avoid 
personal injury. Never make any adjustments with the 
engine running, as serious personal injury can result.

3.21

MAINTENANCE

3

Track Tension

Track tension is critical for maintaining correct suspension
operation. If the track tension is too loose it may cause the track
to slip or “ratchet” on the drive shaft drivers and cause the track
and rear suspension durability problems. If the track is too tight
it will wear down the rail slides, reduce top speeds, cause rear
suspension vibration and cause track and rear suspension
durability problems.

1.

Lift the rear of the machine and place a jack stand or secure
the rear of the machine so that the track is off of the
ground.

2.

Start the engine and slowly let the engine turn the track
over. This will warm up the track for a correct
measurement.

3.

Shut off the engine.

4.

Place a 10 lb. (4.54kg) weight at point (A). Point (A) is 16”
(41cm) ahead of the rear idler shaft (E).

5.

Measure the distance (D) between the rail slider and the
track. This measurement should fall with in the
measurement range for the appropriate vehicle, see chart o
this page.

6.

If adjustment is needed, loosen up the lock nuts (B) on each
side.

7.

Loosen up the idler shaft bolts (F).

8.

Turn each adjuster bolt (C) toward the idler wheel
(clockwise) if you need less of a measurement. Turn the
adjuster bolt (C) toward the front of the sled
(counterclockwise) if you need a greater measurement.

9.

When you achieve the correct tension listed below, torque
the lock nuts (B) and idler shaft bolts on each side to 35 ft-
lb (48 N-m).

NOTE: 

Track alignment affects track tension.

Misalignment will cause excessive wear to the track
and slide rails. Excessive slide wear will appear on
units with the track tension set too tight (or below
measurement specification).

Rear Engine Torque Stop Adjustment

After aligning clutches, adjust the rear torque stop (A) by
loosening the lock nut and rotating the stop so that the clearance
is 0.010” - 0.030” (0.25 - 0.75mm) from the whole surface of the
torque stop.

If replacing a new torque stop, adjust the torque stop so that the
tip (B) is touching the engine case.

o

B

C

A

D

16”(41cm)

E

TRACK

F

SUSPENSION

MEASUREMENT

IQ 121, IQ Touring, IQ LX

7/8" - 1 1/8" 

(2.2-2.9cm)

RMK, Switchback, 340 LX, 

500 XCSP, 550 LX, 

SuperSport, Trail RMK

3/8" - 1/2"

(1-1.3cm)

Wide Track LX

3/4" "- 1"

(1.9-2.5cm)

340 Touring, Trail Touring

1 1/8" - 1 3/8"

(2.9-3.5cm)

= T 

Torque Stop Jam Nut: 15-17 ft-lb. (21-24 N-m)

A

B

TORQUE STOP

3.22

MAINTENANCE

Engine Isolator Limiter Setting

Adjust the front engine isolator limiter so that the stop (D) is
bottomed out on the brace (E).

Hold the engine isolator limiter (D) and torque the jam nut (F)
to specification.

NOTE:  Do not adjust this engine isolator limiter as a
torque stop or damage may occur. The approximate
distance from the face of the isolator to the face of
the engine strap is 0.107" (2.72mm).

CLEANING

Air Filter

The intake foam filter (A) limits snow ingestion into the intake
system. When operating in loose powder, check the top of the
foam filter periodically to remove any accumulation of snow.

NOTE: Do not operate a machine with the intake
filters removed. This may cause carburetor icing
resulting poor fuel economy or engine damage.

Water Sediment Trap

Most Polaris snowmobiles incorporate a patented carburetor
bowl water / sediment traps located at the bottom of each
carburetor. The trap consists of a hose with a plug which should
be inspected for contamination every 1000 miles (1600 km).

1.

Turn the fuel tank supply valve to the “OFF” position.

2.

Position a container or shop towels under the work area to
help catch some of the contaminated gasoline.

3.

Slide the clamp (A) away from the drain plug (B) and
remove it from the sediment tube and drain the
contaminated material from the bowl. Repeat for each
carburetor.

4.

Wipe off the residue from the plug and reinstall the clamps.

Nosepan Care

If your nosepan becomes dirty with soot, you can use Polaris
Carbon Clean (PN 2872890) to remove the soot. 

STORAGE

Chassis And Hood

Proper storage starts by cleaning, washing and waxing the hood,
chassis, upholstery and plastic parts. Clean and touch up with
paint any rusted or bare metal surfaces. Ensure that all corrosive
salt and acids are removed from surfaces before beginning
preservation with waxes and rust inhibitors (grease, oil, or
paint).

If the machine is equipped with a battery, disconnect the battery
cables and clean the cables and battery posts. Fill battery to
proper level with distilled water and charge to full capacity.
Remove and store the battery in a cool dry place.

= T 

Jam Nut: 15-17 ft-lb. (21-24 N-m)

Isolator Limiter touching base

D

E

F

A

A

A

AIR FILTER CLEANING

WARNING

When draining the traps, fuel spillage will occur. Be 
sure to work in a well ventilated area away from 
anything which may cause the fuel to ignite such as an 
open flame, heaters, trouble lights or cigarettes.

A

B